DE112018000959B4 - Wiring harness - Google Patents

Abstract

A wiring harness (10) comprising:a functional sheath (30) formed in the shape of a flat member; andan electrical wire (12) arranged to overlap the functional sheath (30) at least in a part of a region along a longitudinal direction, whereinat least a part of an overlap between an insulation (16) of the electrical wire (12) and the functional sheath (30) is welded, andwherein a connector (20) provided at one end of the electrical wire (12) is welded to the functional sheath (30).

Description

TECHNICAL AREA

The present invention relates to a technology for attaching electric wires to a sheath in a wiring harness for vehicles.

TECHNICAL BACKGROUND

JP 2015 - 072 798 A discloses - for attaching a flat element-shaped sheath to electrical wires - a technique for positioning the sheath with respect to the electrical wires by wrapping a tape around the end portions of the sheath and the electrical wires protruding from the end portions.

US 2002 / 0 062 979 A1 discloses a flat shielding wire harness including a flat wire harness having a plurality of first conductive cores arranged in parallel and an insulating sheath covering the first conductive cores; a thin film foil having a conductive thin film; and an electric wire having a second conductive core and a second sheath covering the second core. The thin film foil is wound around the outer periphery of the flat wire harness with its ends superimposed on each other in the width direction of the flat wire harness, the electric wire resting on the ends, and the conductive layer at the ends of the thin film foil being connected to the second core at the ends. In this configuration, the flat shielding wire harness can safely discharge noise that might penetrate into the core of an electric wire to the outside and prevent an increase in the cost of the wire harness to be assembled.

US 2015 / 0 048 221 A1 discloses a wire harness fixing structure that enables the deformation volume of a center of a plate in a wire harness clamp to be minimized when a wire harness is pulled. The wire harness fixing structure is configured to fix the wire harness to a plate using a wire harness clamp. The wire harness clamp includes a plate consisting of a base portion and a pair of extension portions extending in a direction away from both ends in a longitudinal direction of the base portion. The pair of extension portions are formed narrower than the base portion. The plate and the wire harness are covered and fixed with a self-adhesive film. The locked part, which is latched into a hole of the plate, allows the adhesive film between the plate and the plate to be pressed to and adhere to the outer periphery of the hole.

OVERVIEW OF THE INVENTION

TASKS TO BE SOLVED BY THE INVENTION

For example, an adhesive is also considered as a general technique for attaching the electrical wires to the sheath. However, these methods then require an additional component, such as the adhesive tape or the adhesive.

The object of the present invention is to provide a technique with which the additional component, such as the adhesive tape or the adhesive agent, can be dispensed with when attaching the sheath to the electrical lines.

MEANS TO SOLVE THE TASK

The object is achieved by a cable harness which, according to a first aspect, has the features of claim 1.

A wiring harness according to a second aspect is the wiring harness according to the first aspect, wherein at least a portion of the overlap between the insulation of the electrical line and the functional jacket is ultrasonically welded.

A wire harness according to a third aspect is the wire harness according to the second aspect, wherein an impression produced by pressing a sonotrode of an ultrasonic welding device remains on a surface of the functional sheath which is opposite to a surface on which the electrical line is arranged.

A wiring harness according to a fourth aspect is the wiring harness according to any one of aspects one to three, wherein the functional sheath comprises a sound insulation component having sound insulation properties.

A wiring harness according to a fifth aspect is the wiring harness according to any one of aspects one to four, wherein the functional sheath comprises a shield component capable of shielding the electrical line.

A wire harness according to a sixth aspect is the wire harness according to any one of aspects one to five, wherein the functional cover comprises a protective component having abrasion resistance and capable of protecting the electrical wire from abrasion.

A wire harness according to a seventh aspect is the wire harness according to any one of aspects one to six, wherein the functional cover has a heat radiating component capable of radiating heat of the electrical line.

A wire harness according to an eighth aspect is the wire harness according to the seventh aspect, wherein a high radiation ratio portion having a higher radiation ratio than an inner portion of the heat radiation component is formed on a surface of the heat radiation component.

A wire harness according to a ninth aspect is the wire harness according to any one of aspects one to eight, wherein the functional sheath serves as a tension member subjected to a tensile force exerted on the electrical line.

A wiring harness according to a tenth aspect is the wiring harness according to any one of aspects one to nine, wherein the functional jacket comprises a waterproof component having waterproof properties.

A wire harness according to an eleventh aspect is the wire harness according to any one of aspects one to ten, wherein a fastening component for fastening the electric wire to a mounting object is welded to the functional cover.

EFFECT OF THE INVENTION

According to aspects one to eleven, the sheath and the electric wire can be directly attached to each other by welding. Accordingly, when attaching the sheath to the electric wire, additional components such as an adhesive tape or an adhesive agent can be omitted.

In particular, according to the second aspect, welding can be carried out easily.

In particular, according to the third aspect, the sonotrode of the ultrasonic welding device comes into contact with the sheath in such a way that damage to the electrical line is unlikely.

In particular, according to the fourth aspect, a sound insulation structure can be easily obtained.

In particular, according to the fifth aspect, the electrical line can be easily shielded.

In particular, according to the sixth aspect, the electric line can be easily protected.

In particular, according to the seventh aspect, heat from the electrical line can be easily radiated.

In particular, according to the eighth aspect, the heat radiation effect can be enhanced.

In particular, according to the ninth aspect, even if the pulling force is exerted on the wiring harness, there is hardly any damage to the electrical wire.

In particular, according to the tenth aspect, the electrical line can be easily protected or sealed against water.

In particular, according to the previous aspects, the connector can be easily positioned.

In particular, according to the eleventh aspect, the fastening component can be easily attached.

BRIEF DESCRIPTION OF THE DRAWINGS

• 1 Perspective view of a wiring harness according to a first embodiment.
• 2 View of the wiring harness according to the first embodiment from below.
• 3 Schematic cross-sectional view of the wiring harness in section III-III from 2 .
• 4 Explanatory drawing of an implementation of ultrasonic welding.
• 5 Schematic perspective view of a wiring harness according to a second embodiment.
• 6 Partially enlarged plan view of a wiring harness according to a third embodiment.
• 7 Schematic cross-sectional view of a wire harness according to a fourth embodiment.
• 8th Schematic cross-sectional view of a wire harness according to a fifth embodiment.
• 9 Cross-sectional view of a modified example of a functional sheath.
• 10 Schematic top view of another variation of the functional casing.

EMBODIMENTS OF THE INVENTION

First embodiment

A wire harness according to a first embodiment will be described below. 1 illustrates a perspective view of a wire harness 10 according to the first embodiment. 2 illustrates a bottom view of the wire harness 10 according to the first embodiment. 3 illustrates a schematic cross-sectional view of the wiring harness 10 in section III-III of 2 .

The wiring harness 10 is used as wiring for electrically connecting various electrical devices that are installed in a vehicle, for example. The wiring harness 10 is, for example, routed around or along a dashboard, a roof, or a door in the vehicle. In particular, the wiring harness 10 includes a functional sheath 30 and electrical wires 12. The wiring harness 10 also includes connectors 20 and fastening components 40.

The functional casing 30 has the shape of a flat element (a panel or plate or layer or foil or sheet or sheet or flat element with an extended surface). As in 1 Illustrated, the functional cover 30 has the shape of a rectangular flat member. The shape of the functional cover 30 is not limited to the above-mentioned shape, but can be appropriately changed according to, for example, the placement of the electric wires 12. The functional cover 30 is a component with which the electric wires 12 are covered. The functional cover 30 is a component that has one or more functions for the electric wires 12, such as sound insulation (sound dampening, sound absorption, sound insulation, etc.), protection (abrasion resistance, tensile strength, penetration resistance, etc.), heat radiation, shielding and/or waterproofing, etc. A suitable function of the functional cover 30 is selected according to, for example, the characteristics of the electric wires 12 and the environment of the portion in which the electric wires 12 are arranged. Since the electrical wires 12 are arranged in a portion that may rub against surrounding components, an example will be described in which the functional cover 30 is an abrasion-resistant protective flat member (a protective component).

The protective flat element is made of a flat element material such as polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP) or a nonwoven. If the protective flat element is made of a nonwoven, the protective flat element can be hot-pressed, for example. A spunbond nonwoven or spunbonded nonwoven on which an embossing process has been carried out can also be suitable. As a result, the protective flat element can be hardened. The abrasion resistance of the protective flat element can result from physical properties of its structure or from physical properties of a raw material. Although the protective flat element is in the 1 illustrated example, however, by applying a structure with projections and recesses on an outer surface of the protective sheet, the abrasion resistance of the protective sheet can be increased. In another example, by applying a structure with the hot-pressed nonwoven fabric, the protective sheet can be hardened and the abrasion resistance can be increased. In another example, by using a hard raw material as the material for the protective sheet, the abrasion resistance can be increased.

The electrical lines 12 are arranged such that they overlap with the functional sheath 30 at least in part of an area along a longitudinal direction. In the 1 In the example illustrated, the electrical lines 12 are arranged only on one side of a main surface 31a of the functional casing 30, but they can also partially continue onto one side of the other main surface 31b. The number of electrical lines 12 can be at least one. In the present case, the number of electrical lines 12 is two or more (three in the case illustrated in 1 illustrated example). Insulated electrical wires 12 each having a conductor 14 and an insulation 16 for covering the conductor 14 are used as the electrical wires 12 (see 7 ). The conductor 14 is made of a conductive material such as copper or aluminum. The conductor 14 may be a solid conductor or a stranded conductor. The insulating jacket 16 may be formed, for example, by extruding a plastic such as polyvinyl chloride (PVC), polyethylene (PE) or polypropylene (PP) around the conductor 14 or, for example, by applying wire enamel all around the conductor 14 and oven drying the wire enamel.

At least a portion of an overlap between the insulation 16 of the electrical wires 12 and the functional sheath 30 is welded. In this way, the electrical wires 12 and the functional sheath 30 are attached to each other.

Ultrasonic welding is used as a means of welding. 4 is an explanatory drawing of an implementation of ultrasonic welding. As in 4 As shown, ultrasonic welding is generally carried out by placing two components (in the present case the electrical lines 12 on the one hand and the functional sheath 30 on the other) on top of each other in order to be welded between a sonotrode 82 and an anvil 84 of an ultrasonic welding device 80. The two components are arranged between the sonotrode 82 and the anvil 84 in such a way that surfaces of the two components to be welded are in direct contact with each other.

The sonotrode 82 is in direct contact with one of the two components and applies ultrasonic vibrations to one component. Examples of a transmission mode of the ultrasonic vibrations from the sonotrode 82 are longitudinal vibrations and lateral vibrations, but the transmission mode can be suitably selected depending on the shapes and physical properties of the components to be welded.

The anvil 84 carries the other component of the two components. In the 4 In the example illustrated, a surface of the anvil 84 supporting the electrical wires is formed with a flat surface, but it may also be formed with a curved surface.

When ultrasonic vibrations are applied to one component from the sonotrode 82 while the two components to be welded are superimposed between the sonotrode 82 and the anvil 84, friction or compression occurs due to the applied ultrasonic vibrations and heat energy is released. Accordingly, a part of a surface in direct contact is melted by the heat energy and the two components are bonded together. Only one of the two components may be melted, or both components may be melted. It is considered to be determined according to, for example, the physical properties of the materials from which the two components are formed.

In the 4 In the example illustrated, the sonotrode 82 comes into direct contact with the other main surface 31b of the functional casing 30 to apply the ultrasonic vibrations to the functional casing 30. Here, in ultrasonic welding, in general, an impression created by pressing the sonotrode 82 (hereinafter referred to as "sonotrode impression 34") may remain on the component. Accordingly, the sonotrode impression 34 may also remain on the wire harness 10. Here, the sonotrode 82 is in direct contact with the other main surface 31b of the functional casing 30, so that the sonotrode impression 34 may remain on the other main surface 31b of the functional casing 30, as in 2 . It is contemplated that the sonotrode imprint 34 has a shape corresponding to, for example, a concave-convex shape formed on the sonotrode 82. It is not necessary to let the sonotrode 82 come into direct contact with the other main surface 31b of the functional casing 30; the sonotrode 82 may also come into direct contact with the electric wires 12 to apply the ultrasonic vibrations to the electric wires 12. In this case, the sonotrode imprint may remain on the electric wires 12. However, if the sonotrode 82 comes into direct contact with the other main surface 31b of the functional casing 30, possible damage to the electric wires 12 during the ultrasonic welding can be counteracted.

A region of the electrical lines 12 welded to the functional sheath 30 in a longitudinal direction may be seamlessly aligned along the longitudinal direction of the electrical lines 12, or it may comprise a portion that is partially separated along the longitudinal direction of the electrical lines 12. In the 2 In the example illustrated, the ultrasonic welding is carried out intermittently or at periodic intervals so that it has the portion which is partially separated along the longitudinal direction of the electric wires 12. For example, an extension of a welding point and an interval between adjacent welding points can be suitably selected according to a desired bonding strength. In the example illustrated in 2 In the example illustrated, ultrasonic welding is carried out at periodic intervals with a constant step size along the longitudinal direction of the electrical lines 12, but there may also be a part in which ultrasonic welding is carried out with a different step size.

A circumferential region of the electrical wires 12 welded to the functional sheath 30 may be an entire circumferential region or a portion of that region. If only a portion of the circumferential region of the electrical wires 12 is welded, the region may be equal to or less than one-half of the circumference, or it may be equal to or less than one-quarter of the circumference.

When performing ultrasonic welding, at least one of the two components (in this case the insulation 16 of the electrical line gen 12 and the functional sheath 30) on the direct contact surface a thermoplastic resin. Here, preferably both of the two components have thermoplastic resins with similar melting points on their direct contact surfaces. More preferably both of the two components have the same thermoplastic resin on their direct contact surfaces. Accordingly, both of the two components are melted and the bonding strength can be increased.

The electric wires 12 may be power wires or signal wires in terms of use. The electric wires 12 may be thick or thin in terms of thickness. The electric wires 12 may be round wires or square wires in terms of cross-sectional shape. Here, however, each of the direct contact surfaces of the two components when ultrasonic welding is started preferably has a convex shape so that a contact area is reduced. From this point of view, the round wire has the convex shape in any position in the circumferential direction so that its specific orientation is irrelevant. Accordingly, the round wire has a shape suitable for ultrasonic welding.

Ends of the electric wires 12 are integrated into the connectors 20. For example, when the wire harness 10 is arranged at a designated installation location in a vehicle or the like, the connectors 20 are connected to connectors of the various electric devices installed in the vehicle. Accordingly, the wire harness 10 is used, for example, as wiring for electrically connecting the various electric devices installed in the vehicle.

Here, the connectors 20 are also welded to the functional casing 30. A part of an outer surface of a connector housing 21 in the connectors 20 has an overlap with the functional casing 30, and at least a part of the overlap portion is welded. The connector housing 21 is a component that is integrally molded (injection molded) using, for example, a plastic as a material. In the 2 In the example illustrated, the sonotrode imprint 34 has remained on one side of the functional casing 30, but the sonotrode imprint may remain on one side of the connector housing 21.

A welding point in the connector housing 21 is preferably a point that does not block a mating process with a counterpart connector. For example, in the 2 In the example illustrated, a peripheral part of a portion from which the electrical wires 12 extend outward in the connector housing 21 is welded, but it is also conceivable that a part of the outer surface of the connector housing 21 protrudes, has a projection piece and the projection piece is welded.

It is not necessary for the connectors 20 to be welded to the functional sheath 30. In this case, the connector 20 may also be attached to the functional sheath 30 by other means, such as adhesive tape or glue, but this does not have to be the case.

In this case, as in 3 As illustrated, the connectors 20 are insulation displacement type connectors 20. More specifically, the connector housing 21 is configured from a first component 23 and a second component 24 that can be inserted into the first component 23.

The first component 23 can hold an insulation displacement contact 26, with an insulation displacement part 27 exposed to the outside. The insulation displacement part 27 is part of the insulation displacement contact 26 and can be connected to the insulated electrical lines 12 by means of pressure. The first component 23 accommodates a partner connector 28 to be connected to a partner conductor, which can be connected to the partner conductor. The partner connector 28 is part of the insulation displacement contact 26. The second component 24 is arranged opposite a section of the first component 23 for holding the insulation displacement part 27 and can press the insulated electrical lines 12 towards the insulation displacement part 27. The second component 24 presses the insulated electrical wires 12 towards the insulation displacement part 27, while the non-stripped electrical wires 12 are located on the insulation displacement part 27 of the insulation displacement contact 26, which is held by the first component 23. As a result, a part of the insulation displacement part 27 breaks the insulation 16 of the insulated electrical wires 12 such that it rests on the conductor 14 and is connected to it.

In this case, the 2 In the example illustrated, all of the three electrical wires 12 are welded to the functional sheath 30. If the number of electrical wires 12 included in the wiring harness 10 is two or more, the electrical wires 12 may include the electrical wires 12 that are not welded to the functional sheath 30. The three electrical wires 12 are welded to the functional sheath 30 in the 2 example illustrated in the same way. If the wiring harness 10 has the plurality of electrical wires 12, the are welded to the functional sheath 30, at least some of the welding shapes, such as a welding agent and a welding region, of the individual welded electrical lines 12 may differ from one another.

The three electrical lines 12 are in the 1 example illustrated are connected to the same connectors 20. If the number of electrical wires 12 included in the wiring harness 10 is two or more, the electrical wires 12 may include electrical wires 12 connected to different connectors 20.

The electrical cables 12 are in the 1 illustrated example. The electric wires 12 may be curved. If the number of electric wires 12 included in the wire harness 10 is two or more, both linearly arranged electric wires 12 and curved electric wires 12 may be present at the same time. In this case, the plurality of electric wires 12 may have branches on the functional sheath 30.

The electrical cables 12 are in the 1 In the example illustrated, the electric wires 12 are arranged in the width direction close to a center of the functional casing 30. A path along which the electric wires 12 are arranged with respect to the functional casing 30 is not limited to the path described above. For example, the electric wires 12 may be arranged in the width direction close to an end of the functional casing 30. For example, the electric wires 12 may run diagonally to the functional casing 30.

The fastening components 40 are components for fastening the electrical lines 12 to an assembly object 70 such as a body panel or a rod component. The fastening components 40 are also welded to the functional sheath 30. In the 2 In the example illustrated, the sonotrode imprint 34 has remained on the side of the functional casing 30, but the sonotrode imprint may remain on one side of the fastening components 40. The fastening components 40 are here components referred to as clamps, clamps or clips and they each comprise a column part 44 and a wing part 46 which extends from the tip of the column part 44 and is integrally formed (injection molded) using, for example, a plastic as the material.

In the fixing component 40, a plate part 42 is provided which supports the column part 44, and the plate part 42 and the functional cover 30 are welded together. As the plate part 42, an existing component such as a protruding piece wrapped with tape into a so-called adhesive clip may be used, or a new dedicated component may be used.

In the 2 In the example illustrated, the fastening components 40 are mounted so as to protrude on one side of the other main surface 31b which is arranged on a side opposite to the one main surface 31a on which the electric wires 12 are arranged. Accordingly, direct contact of the electric wires 12 with the mounting object 70 is prevented so that the electric wires 12 can be protected from the mounting object 70. The fastening components 40 may be mounted so as to protrude on the side of the one main surface 31a.

According to the wire harness 10 having the above-described configuration, the cover 30 and the electric wires 12 can be directly fixed to each other by welding. Accordingly, when attaching the cover 30 to the electric wires 12, the other component such as the tape or the adhesive can be omitted.

At least the part of the overlap between the insulation cover 16 of the electrical lines 12 and the functional sheath 30 is ultrasonically welded so that welding can be carried out easily.

The sonotrode 82 of the ultrasonic welding machine 80 comes into contact with the casing 30, so that damage to the electrical lines 12 is unlikely. In the functional casing 30, the sonotrode impression 34 formed by pressing the sonotrode 82 of the ultrasonic welding machine 80 remains on one surface (the other main surface 31b in the 1 example shown) which is opposite to a surface on which the electrical lines 12 are arranged (which is a main surface 31a in the example shown in 1 illustrated example).

Since the functional sheath 30 is abrasion resistant, the electrical lines 12 can be easily protected.

Since the connectors 20 provided at the ends of the electrical lines 12 are also welded to the functional sheath 30, the connectors 20 can be easily positioned.

Since the fastening components 40 for fastening the electrical lines 12 to the assembly object 70 are also welded to the functional sheath 30, the fastening components 40 can be easily attached.

Second embodiment

Next, a wire harness 110 according to a second embodiment will be described. 5 is a schematic perspective view of the wire harness 110 according to the second embodiment. In the following description of the embodiments, constituent elements that are the same as those described above are given the same reference numerals and their description is omitted.

The wire harness 110 according to the second embodiment differs from the wire harness 10 according to the first embodiment in that a functional cover 130 is a shielding component having shielding properties.

The shield component is formed of, for example, a metal foil, a metal net, a laminate of a metal foil and a plastic layer, or a sheet material made of a conductive plastic. When a metal component such as the metal foil or the metal net comes into direct contact with the electrical wires 12, it is considered that only the insulation 16 is melted and welded to, for example, the metal foil or the metal net.

Here, the shield component is flexible to the extent that it can be wound around the electric wires 12. The shield component is wound around the electric wires 12 to cover the surroundings of the electric wires 12 with the shield component, and the electric wires 12 are fastened to one another by welding. This enables the shield component to shield the electric wires 12 inside it. The shield component has fixing pieces 132 each with a screw hole 134. The shield component is grounded by fixing the fixing pieces 132 with screws, for example, to a body panel. The grounding method may include leading out a discharge line adjacent to the shield component, or a part of the electric wires 12 attached to the shield component may be electrically connected to use the part of the electric wires 12 as a discharge line.

The electrical lines 12 can be easily shielded in the wiring harness 110 with such an arrangement.

Third embodiment

Next, a wire harness 210 according to a third embodiment will be described. 6 illustrates an enlarged partial plan view of the wire harness 210 according to the third embodiment.

The wire harness 210 according to the third embodiment differs from the wire harness 10 according to the first embodiment in that a functional cover 230 is a tension member subjected to a tensile force exerted on the electrical wires 12.

For example, a flat element material that is less stretchable than the electrical wires 12 is used as the functional sheath 230, and the part of the electrical wires 12 that is attached to the functional sheath 230 is, as in 6 , slack or with an allowance or a stock length. For example, it is considered that the electric wires 12 and the functional cover 230 are intermittently welded along the longitudinal direction, and that the electric wires 12 have the slack (the allowance, the stock length) in a portion between the adjacent welding points. This enables the functional cover 230 to absorb the tensile force exerted on the wire harness 210 along the longitudinal direction of the electric wires 12. As a result, excessive tensile force can be prevented from being exerted on the electric wires 12. In 6 Partial weld spots WP are exaggeratedly represented by square-shaped graphics.

With such a configuration, even if the tensile force is exerted on the wire harness 210, the electric wires 12 are hardly damaged.

Fourth embodiment

Next, a wire harness 310 according to a fourth embodiment will be described. 7 is a schematic cross-sectional view of the wire harness 310 according to the fourth embodiment. It should be noted that 7 a cross-sectional view of the wiring harness 310 in a cutting plane perpendicular to the longitudinal direction of the electrical lines 12.

The wiring harness 310 according to the fourth embodiment differs from the wiring harness 10 according to the first embodiment, a functional sheath 330 is a water-repellent flat element with water-repellent properties.

The water-repellent flat element is, for example, a polyethylene flat element. The water-repellent flat element is flexible to the extent that it can be wound around the electrical lines 12. The water-repellent flat element encloses the electrical lines 12, whereby the electrical lines 12 and the water-repellent flat element are welded together. This can, for example, prevent water from penetrating into the interior of the water-repellent flat element. In the 7 In the example illustrated, the water-repellent flat member has a part that is not welded but covers the welding point WP, but such a configuration is not necessarily present. A winding end portion of the water-repellent flat member can be fixed without gaps, for example, by an adhesive tape or an adhesive. It is not necessary for the water-repellent flat member to cover an entire circumference of the electrical wires 12. For example, the water-repellent flat member can be arranged only on one surface side of the electrical wires 12 in order to prevent the electrical wires 12 from being wetted with water from one side. In this case, the water-repellent flat member does not need to be flexible to the extent that it can be wound around the electrical wires 12.

The electrical lines 12 can be easily protected against water in the cable harness 310 with such a design.

Fifth embodiment

Next, a wire harness 410 according to a fifth embodiment will be described. 8th illustrates a schematic cross-sectional view of the wire harness 410 according to the fifth embodiment.

The wire harness 410 according to the fifth embodiment differs from the wire harness 10 according to the first embodiment in that a functional sheath 430 is wound around the electrical wires 12 and a fastening component 440 maintains the wound state.

In this case, a through hole 432 into which a fastening portion of the fastening component 440 can be inserted may be formed in the functional case 430; the through hole 432 may be formed in a portion overlapping a portion in which the fastening component 440 is provided.

The wound state of the functional cover 430 can be easily maintained in the wire harness 410 with such a configuration.

Variation example

In the above description, the welding means is ultrasonic welding, but the welding means is not limited to ultrasonic welding. For example, thermal welding such as resistance welding or laser welding may also be applicable.

Although the first embodiment describes that the protective sheet has abrasion resistance, this is not necessary. The protective sheet may have penetration resistance. In this case, the protective sheet may have the penetration resistance required for use under conditions such as those encountered in a vehicle.

Although the first embodiment describes that the functional casing 30 is a protective flat member, this is not necessary. The functional casing 30 may also be a sound-absorbing flat member (a sound-absorbing component). The sound-absorbing flat member is, for example, a flat member component made of a nonwoven fabric or a foamed plastic. If the functional casing 30 is a sound-absorbing flat member, a structure is also conceivable in which the sound-absorbing flat member encloses the electrical wires 12 welded to the functional casing 30. This can improve the sound-absorbing properties. The sound-absorbing flat member may be folded to enclose the electrical wires 12, or the electrical wires 12 may be surrounded on one side by a first sound-absorbing flat member to which the electrical wires 12 are welded, and on the other side by another sound-absorbing flat member provided separately from the first sound-absorbing flat member.

Although the second embodiment describes that the functional casing 130 is made of a metal, the functional casing 130 made of a metal may also be used not as a shield component but as a heat radiation component. If the functional casing 130 is used as a heat radiation component, a configuration conceivable in which the functional sheath 130 and the electrical line 12 abut one another at least in a partial area and at least a partial area of the functional sheath 130 is exposed on the outside.

If the functional casing 130 is used as a heat radiating component, metals are generally superior in terms of thermal conductivity, but inferior in terms of emissivity. On the surfaces of the functional casing 130, as in 9 high emissivity sections 138 may be formed. The high emissivity sections 138 are sections having an emissivity that is greater than that of an inner section 137.

According to Wien's displacement law, the peak wavelength of light emitted by an object by thermal radiation is inversely proportional to the temperature of the object. It is also known that the same material can have different emissivity values depending on the temperature of the object (wavelength of the light). Since it is desired to increase the emissivity of the vehicle-mounted wiring harness 110, the high emissivity portions 138 can have a higher emissivity corresponding to the peak wavelength in a high temperature zone generated in a use environment of the vehicle.

To form the high emissivity portions 138, the surfaces of the functional casing 130 are subjected to a surface treatment to increase the emissivity. It is contemplated that the high emissivity portions 138 may be, for example, oxide films formed by oxidation of the metal surfaces of the inner portion 137. The high emissivity portions 138 may be, for example, plated portions or painted portions subjected to a plating process or a painting process on the surface of a component of the inner portion 137. The paint to be used in the painting process may be, for example, a synthetic resin.

In the 9 In the example illustrated, the high-emissivity sections 138 are formed on both main surfaces of the functional casing 130, but the high-emissivity section 138 can also be formed on only one of the main surfaces. If the high-emissivity section 138 is formed on only one of the main surfaces of the functional casing 130, it can be formed on the main surface on which the electrical lines 12 are arranged, or on the main surface opposite thereto. The high-emissivity section 138 can be formed over the entire area of the main surface of the functional casing 130 or only on a partial area thereof. If the high-emissivity section 138 is formed on only a partial area of the main surface of the functional casing 130, it can - but does not have to - be formed on a section in which the electrical lines 12 are arranged. The high-emissivity section 138 can preferably be formed on an outward-facing plane of the functional casing 130. If the high emissivity portion 138 is formed on a portion of the functional cover 130 from which heat dissipation by conduction or convection is not expected when the wire harness 110 is mounted on a vehicle, then heat dissipation from that portion via the high emissivity portion 138 is more effective.

Forming the high emissivity portion enables more efficient heat radiation. Since the temperature rise of the electrical wires 12 can be kept small, the electrical wires 12 can be made smaller. Since the heat storage requirement decreases with increasing heat radiation of the functional sheath 130, the functional sheath 130 can be made thinner.

The functional cover 30 may have different tensile strengths in a first direction and a second direction that are perpendicular to each other and extend in the direction of extension of the main surface of the functional cover 30. The direction having the larger tensile strength is preferably the same as the direction of extension of the electric wires 12 in the functional cover 30. This is because, when the wire harness 10 is mounted on a vehicle, the functional cover 30 can be pulled more in the direction of extension of the electric wires 12 than in a direction perpendicular to the direction of extension of the electric wires 12, and the pulling force is larger in the first case than in the second case. By making the direction of the larger tensile strength the same as the direction of extension of the electric wires 12, the wire harness 10 is hardly damaged even if the wire harness 10 is strongly pulled in the direction of extension; in particular, this makes it easy to mount the wire harness 10 on the vehicle. The functional cover 30 having such anisotropy of tensile strength is suitable, for example, as the functional cover 230 according to the third embodiment to be used as a tension member.

The functional cover 30 may be any as long as the tensile strength in the first direction and the second direction are different. Any materials and manufacturing methods are applicable. The functional cover 30 having different tensile strength in the first and second directions can be obtained by drawing an extrusion-formed sheet material such as a uniaxially oriented film or a biaxially oriented film during manufacturing. Nonwoven fabrics such as spunbonded fabrics usually have a high tensile strength in the fiber longitudinal direction.

As in 10 For example, as illustrated in FIG. 1, the functional sheath 30 may have an additional shape with different tensile strength in the first and second directions. In the case of the 10 In the example of a functional casing 530 illustrated, changing the shape of compressed portions 538 results in different tensile strengths. More specifically, the functional casing 530, after being subjected to a compression process such as stamping, has the compressed portions 538 that are more compressed than a surrounding portion 537. The compressed portions 538 are formed elongated, such as rectangles or ovals. In the functional casing 530 in this case, it is considered that the tensile strength of the compressed portions 538 along a longitudinal direction is greater than the tensile strength of the compressed portions 538 in a transverse direction.

In the 10 In the example illustrated, a plurality of compressed sections 538 are formed such that they are arranged next to each other in the vertical and horizontal directions of the image plane of the figure. In both directions, the plurality of compressed sections 538 are aligned in the same way. More specifically, the plurality of compressed sections 538 are arranged next to each other such that their transverse direction coincides with the vertical direction of the image plane. The plurality of compressed sections 538 are also arranged next to each other such that their longitudinal direction coincides with the horizontal direction of the image plane. The functional casing 530 can in this case be arranged at least at a position of a middle section in the horizontal direction of the image plane, at any position along the horizontal direction of the image plane as in 10 illustrated, and having the compressed portions 538 at least in a partial area along the vertical direction of the image plane at that position. This is because if the compressed portions 538 are not formed at the position of the central portion of the functional case 530 along the horizontal direction of the image plane and along the vertical direction of the image plane at that position, the stress is concentrated on the central portion when the tensile force is applied to the functional case 530 in the horizontal direction of the image plane.

The functional sheath 30 may have different extensibility in the first direction described above and the second direction described above. If the electrical wires 12 are arranged such that they run linearly in a section to which the functional sheath 30 is attached, then the direction in which the functional sheath 30 is less extensible is preferably the same as the direction in which the electrical wires 12 run. This makes it easier to maintain the linear course of the electrical wires 12. The less extensible the electrical wires 12 are, the higher the load share of the tensile force on the electrical wires 12 absorbed by the functional sheath 30. It is therefore to be expected that it offers an advantage if the functional sheath 30 serves as a tension member. If the functional sheath 30 is wound around the electrical wires 12 or if the functional sheath 30 is wound around a rod component for reinforcement with the electrical wires 12 placed around the rod component, then the electrical wires 12 are easy to wind because the electrical wires 12 can be wound in a direction in which the functional sheath 30 is more stretchable.

If the electrical lines 12 are arranged such that they run with a curvature in a section to which the functional sheath 30 is attached, then the direction in which the functional sheath 30 is more stretchable is preferably the same as the direction in which the electrical lines 12 run. This allows the functional sheath 30 to follow the curvature of the electrical lines 12.

The functional cover 30 may be any as long as the stretchability in the first direction and the second direction is different. Any materials and manufacturing methods are applicable. The functional cover 30 having different stretchability in the first direction and the second direction can be obtained by drawing a flat element material formed by extrusion, such as a uniaxially oriented film or a biaxially oriented film, during manufacture. Nonwoven fabrics, such as spunbonded fabrics, are usually more stretchable in the transverse direction of the fiber length.

The functional sheath 30 may, for example, have an additional shape with different extensibility in the first and second directions. In the 10 In the example of the functional sheath 530 illustrated and described above, the compressed portions 538 having the above-mentioned shape are more stretchable in the vertical direction of the image plane than in the horizontal direction of the image plane.

As for the first and second directions, the direction with greater tensile strength may be the same or different from the direction with less elongation. The first and second directions may have different tensile strengths and equal elongation, or they may have equal tensile strengths and different elongation.

In the above description, the insulation 16 that directly covers the conductor 14 in an electric wire 12 is directly welded to the functional sheath 30, but this configuration is not necessarily present. For example, it is also contemplated that in an electric wire having multiple insulations, such as a shielded wire having a conductor, a first insulation covering the conductor, a shield layer covering the first insulation, and a second insulation covering the shield layer, the second insulation, which is an outermost layer, and a functional sheath are welded together. It is also contemplated, for example, that in a cable having multiple electric wires 12 and a cable sheath covering the multiple electric wires 12, the cable sheath and a functional sheath are welded together. In this case, the cable sheath can be considered as one of the insulations of the electric wires 12.

Although the use of the insulation displacement connectors 20 as connectors 20 is described above, this is not necessary. The connectors can, for example, accommodate contacts that are connected to the ends of the electrical lines 12.

The configurations described in the embodiments and the modifications thereof can be suitably combined as long as they are not incompatible with each other. For example, a functional casing can be a combination of several flat element materials with different functions.

While the present invention has been described in detail, the foregoing description is in all aspects illustrative and not limiting of the invention. It is therefore to be understood that numerous modifications and variations can be devised without departing from the scope of the invention.

LIST OF REFERENCE SYMBOLS

10

Wiring harness

12

electrical line

14

Director

16

insulation

20

Interconnects

21

Connector housing

23

first component

24

second component

26

Insulation displacement contact

27

Insulation displacement part

30

functional sheath

31a

a main area

31b

other main area

34

Sonotrode impression

40

Fastening component

42

Plate part

44

Column part

46

Wing part

80

Ultrasonic welding machine

82

Sonotrode

84

anvil

Claims (11)

A wiring harness (10) comprising: a functional sheath (30) formed in the shape of a flat member; and an electric wire (12) arranged to overlap the functional sheath (30) at least in a part of a region along a longitudinal direction, wherein at least a part of an overlap between an insulation (16) of the electric wire (12) and the functional sheath (30) is welded, and wherein a connector (20) provided at one end of the electric wire (12) is welded to the functional sheath (30). Wiring harness (10) to Claim 1 , wherein at least a part of the overlap between the insulation (16) of the electrical line (12) and the functional casing (30) is ultrasonically welded. Wiring harness (10) to Claim 2 , wherein an impression (34) produced by pressing in a sonotrode (82) of an ultrasonic welding device (80) remains on a surface of the functional casing (30) which is opposite a surface on which the electrical line (12) is arranged. Wiring harness (10) according to one of the Claims 1 until 3 , wherein the functional casing (30) comprises a sound insulation component with sound insulation properties. Wiring harness (10) according to one of the Claims 1 until 4 , wherein the functional sheath (30) has a shielding component capable of shielding the electrical line (12). Wiring harness (10) according to one of the Claims 1 until 5 , wherein the functional sheath (30) comprises a protective component which has abrasion resistance and is capable of protecting the electrical line (12) from abrasion. Wiring harness (10) according to one of the Claims 1 until 6 , wherein the functional sheath (30) has a heat radiation component capable of radiating heat from the electrical line (12). Wiring harness (10) to Claim 7 wherein a high radiation ratio portion having a higher radiation ratio than an inner portion of the heat radiating component is formed on a surface of the heat radiating component. Wiring harness (10) according to one of the Claims 1 until 8th , wherein the functional sheath (30) serves as a tension member which is subjected to a tensile force exerted on the electrical line (12). Wiring harness (10) according to one of the Claims 1 until 9 , wherein the functional casing (30) comprises a waterproofing component with waterproofing properties. Wiring harness (10) according to one of the Claims 1 until 10 , wherein a fastening component for fastening the electrical line (12) to a mounting object (70) is welded to the functional sheath (30).

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